The Volvo D 5204 T3 is a 2,401 cc, inline‑five turbo‑diesel engine produced between 2001 and 2005. It features a cast iron block, aluminum cylinder head, double overhead camshafts (DOHC), and a variable geometry turbocharger (VGT). This engine was designed for robust performance, delivering 120 kW (163 PS) and 340 Nm of torque, with the VGT system ensuring strong low-rpm torque for effortless towing and highway merging.
Fitted primarily to the P2 platform S60, V70, and XC70 models, the D 5204 T3 was engineered for drivers prioritizing durability, long-distance comfort, and substantial pulling power. Emissions compliance for its production run was achieved through exhaust gas recirculation (EGR), targeting Euro 3 standards for most markets.
A documented concern involves premature failure of the VGT actuator mechanism, leading to boost control faults. This issue, referenced in Volvo Technical Service Bulletin TSB‑02‑015, is often attributed to carbon buildup and heat cycling. In 2004, Volvo introduced revised actuator components to improve longevity.
Production years 2001–2005 meet Euro 3 standards (VCA UK Type Approval #VCA/EMS/VOLVO-D5).
The Volvo D 5204 T3 is a 2,401 cc inline‑five turbo‑diesel engineered for executive sedans and wagons (2001-2005). It combines a Bosch VP44 rotary injection pump with a single variable‑geometry turbocharger to deliver substantial low-end pulling power and smooth cruising. Designed to meet Euro 3 standards, it prioritizes torque and durability over ultimate fuel economy.
| Parameter | Value | Source |
|---|---|---|
| Displacement | 2,401 cc | |
| Fuel type | Diesel | |
| Configuration | Inline‑5, DOHC, 20‑valve | |
| Aspiration | Turbocharged | |
| Bore × stroke | 81.0 mm × 93.2 mm | |
| Power output | 120 kW (163 PS) | |
| Torque | 340 Nm @ 1,750–2,750 rpm | |
| Fuel system | Bosch VP44 rotary injection pump | |
| Emissions standard | Euro 3 | |
| Compression ratio | 18.3:1 | |
| Cooling system | Water‑cooled | |
| Turbocharger | Single variable‑geometry turbo (Garrett) | |
| Timing system | Chain-driven (front-mounted) | |
| Oil type | Volvo VDS-3 (SAE 10W‑40) | |
| Dry weight | 185 kg |
The inline-five configuration provides a unique, smooth power delivery but requires adherence to 15,000 km oil change intervals using Volvo VDS-3 spec oil to protect the turbo and injection pump. The Bosch VP44 pump is sensitive to fuel quality; ultra-low-sulfur diesel (ULSD) meeting EN 590 is mandatory to prevent premature wear. The VGT actuator is a known wear item; symptoms like boost lag or fault codes should prompt inspection per TSB-02-015. EGR system cleaning is recommended every 60,000 km to maintain performance.
Oil Specs: Requires Volvo VDS-3 specification (Volvo Owner's Manual). ACEA B3/B4 is the minimum acceptable standard.
Emissions: Euro 3 certification applies to all 2001–2005 models (VCA Type Approval #VCA/EMS/VOLVO-D5).
Power Ratings: Measured under ISO 1585 standards. Output is consistent across model range (Volvo TIS Doc. V26015).
Volvo Technical Information System (TIS): Docs V24680, V25142, V25631, TSB-02-015
VCA Type Approval Database (VCA/EMS/VOLVO-D5)
ISO International: 1585 Engine Power Test Code
The Volvo D 5204 T3 was used across Volvo's P2 platform with longitudinal mounting. This engine received platform-specific adaptations-reinforced engine mounts in the XC70 for off-road use. All adaptations are documented in OEM technical bulletins.
Locate the engine code stamped on the front of the cylinder block, near the timing cover (Volvo TIS V24890). The 8th VIN digit for D5 models is typically 'D'. The engine features a distinctive inline-five layout with a large Garrett VGT turbo mounted at the front. Critical differentiation from later D5 engines: D 5204 T3 uses a Bosch VP44 mechanical injection pump, whereas later variants (D 5204 T4/T5) use common-rail systems. Service parts, particularly for the fuel system and turbo, are specific to the T3 variant.
The D 5204 T3's primary reliability risk is VGT actuator failure, with elevated incidence in high-mileage vehicles. Volvo internal service data indicated a significant number of actuators required replacement before 150,000 km, while owner reports frequently cite boost-related drivability issues. Extended highway driving and infrequent oil changes accelerate carbon buildup, making preventative cleaning and using the correct oil specification critical.
Analysis derived from Volvo technical bulletins (2002-2006) and aggregated European owner association failure reports (2005-2020). Repair procedures should follow manufacturer guidelines.
Find answers to most commonly asked questions about VOLVO D-5204-T3.
Comprehensive technical documentation and regulatory references
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VOLVO Official Site
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EUR-Lex
EU emissions and type-approval regulations (e.g., CELEX:32007R0715, CELEX:32017R1151).
GOV.UK: Vehicle Approval & V5C
UK vehicle approval processes, import rules, and MoT guidance.
DVLA: Engine Changes & MoT
Official guidance on engine swaps and inspection implications.
Vehicle Certification Agency (VCA)
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Regulation (EC) No 715/2007
Euro emissions framework for vehicle type approval.
Commission Regulation (EU) 2017/1151
WLTP and RDE testing procedures for emissions certification.
GOV.UK: Vehicle Approval
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